In the spring I installed the full IPD poly bushing kit in my 240. A major project to say the least. If you recall this was the story of me completing the job because it was "too hard" for the local shop. Anyway, with the project finished all was happy and good.

Now I am getting some front-end clunks. I have retorqued the control arm bolts multiple times. I see no indications of movement in the front cross member. Today I tried retorquing again with wheels loaded and myself pressing up and down on the front end in an attempt to settle things. Clunk.

The clunk occurs when backing down my driveway and then again when I make my first stop. After this things are quite for a bit.

I think the rear control arm bushing sleeve may be shifting in the bucket. I noticed a little gap between the sleeve and the bucket. I took the car out and slammed on the brakes and this seems to have pushed the sleeve fully in.

Anybody had similar experiences? Should I take it to the shop to have the sleeve tack-welded in place (assuming this is really the problem)? If so, does everything need to be taken apart for the 3rd time?

Thanks